00:00:08
welcome back to Monroe live now recently
00:00:11
we had introduced you to the byd shark
00:00:13
this vehicle is being torn down for a
00:00:15
very specific purpose so unfortunately
00:00:17
we don't have a lot of time with it so
00:00:19
while we do have some time I wanted to
00:00:21
point out a few of the things that I can
00:00:22
actually get to without getting to a
00:00:24
complete vehicle tear down as you can
00:00:26
see for the interior the seats have been
00:00:29
pulled out and the center console has
00:00:30
been pulled out I did want to go into a
00:00:33
little bit on that center
00:00:34
console so you see here the air ducts
00:00:37
that is piping the ventilation from the
00:00:41
HVAC unit through the center console to
00:00:44
the rear occupant so that type of a duct
00:00:47
structure is exposed within the vehicle
00:00:50
now that structure is actually a
00:00:51
multi-piece structure sometimes you can
00:00:54
blow mold that all in one piece I think
00:00:57
it's interesting here you see the little
00:00:59
rivets
00:01:00
it's multiple pieces that have been
00:01:02
riveted together so even though it's
00:01:05
multiple pieces you really can't take it
00:01:07
apart as a customer but it would have
00:01:10
been nice if they were able to integrate
00:01:11
that all into one blow mold rather than
00:01:14
this type of an assembly you see the two
00:01:17
brackets sticking
00:01:18
up those are providing the lower
00:01:21
structure for actually mounting that
00:01:22
center console uh just want to make
00:01:25
mention of it some center consoles can
00:01:27
mount directly to a vehicle sometimes
00:01:28
you need some sort of a structure
00:01:31
now I've worked on a vehicle where that
00:01:32
has been the only structure and a
00:01:35
surface components of the center console
00:01:38
attached directly to that this one does
00:01:40
have an internal structure which isn't
00:01:42
uncommon we've seen that on many center
00:01:44
consoles but let's go ahead and have a
00:01:46
look at what those parts look like so
00:01:49
here's the center console
00:01:50
removed now style-wise
00:01:53
you can pick any style you want okay
00:01:57
this is cladding this is a Surface
00:01:59
decoration
00:02:00
I'm really impressed when the a surface
00:02:02
feature is also the structure but we
00:02:05
don't really have that here let's take a
00:02:10
look this is our internal structure you
00:02:14
can see we have this wall and then we
00:02:16
have the decorative pieces that snap
00:02:18
into that wall this is very very common
00:02:22
however if I were to try and design
00:02:24
something to be as efficient as possible
00:02:26
I would love to be able to integrate
00:02:28
this component into this
00:02:30
component this is just injection molding
00:02:34
there's no painting on this there's no
00:02:36
other type of styling so if this is just
00:02:37
injection molding and this is injection
00:02:40
molding and we have pop out windows
00:02:44
right here to get to the bolt location
00:02:46
for that
00:02:47
bracket Why Can't This Be the structure
00:02:51
itself and I have seen some Vehicles
00:02:54
where they have allowed the a surface to
00:02:56
be the structure unfortunately not on
00:02:58
this one when we talked about this in
00:03:01
vehicle I had mentioned
00:03:03
this hinge now the hinge and the lack of
00:03:07
any type of a striker and any type of a
00:03:10
latch there is tension designed into
00:03:13
this hinge to provide the force to hold
00:03:15
that in position and that's actually
00:03:19
what's also holding it
00:03:21
closed why is that an improvement
00:03:26
well I don't have a
00:03:28
latch here's a
00:03:31
latch this is an assembly of injection
00:03:34
molded Parts there's pins there's
00:03:36
Springs this would then be mounted
00:03:38
inside of the lid now there are
00:03:40
Fasteners that are attaching that some
00:03:43
sort of a closeout panel and then I
00:03:45
would have to have some sort of a hole
00:03:48
here I once worked for a company that
00:03:51
purchased a company that made these
00:03:54
components now if I'm looking at this
00:03:55
from a cost perspective and again I am
00:03:58
the company that makes this component
00:04:00
am I ever going to suggest to the
00:04:02
customer we don't need this anymore
00:04:05
let's stop making these no I'm not going
00:04:07
to do
00:04:08
that okay is anyone within the OEM going
00:04:13
to make that
00:04:14
suggestion if this is what they've
00:04:16
always done maybe
00:04:20
not this is a cost savings this is a
00:04:23
component savings this is a labor
00:04:25
savings I'm no longer installing that I
00:04:27
no longer have to worry about the
00:04:28
quality issues of that
00:04:30
assembly but am I providing a feature
00:04:35
that is beneficial to the customer to
00:04:37
you do I have to reduce the selling
00:04:40
price of my vehicle because I do not
00:04:43
have this
00:04:44
component I would argue no so if I can
00:04:48
admit paying for this component and I
00:04:51
don't have to reduce the cost of my
00:04:52
vehicle because I don't have that
00:04:54
component that is a net benefit to the
00:04:57
OEM having those types of benefits
00:05:01
enable them to be more profitable being
00:05:05
profitable means that they can be more
00:05:07
successful uh they can invest in more
00:05:09
things in the
00:05:10
future or it means that they have the
00:05:14
opportunity to lower their prices if
00:05:16
they need to because again they're no
00:05:18
longer paying for that component
00:05:20
component cost reduction assembly
00:05:23
reduction it gives them
00:05:26
leverage and you need leverage if you
00:05:29
are competing in a worldwide Market we
00:05:31
have had the discussion quite a lot
00:05:34
recently about competition between a lot
00:05:38
of startup automakers a lot of
00:05:41
automakers from other parts of the world
00:05:43
that may or may not have different types
00:05:44
of regulations different types of
00:05:46
requirements but this is a feature that
00:05:49
is a decision on the oem's part they
00:05:52
have to make that decision whether they
00:05:53
have it or whether they don't that
00:05:56
decision may or may not affect the cost
00:05:59
of the selling or the selling price of
00:06:01
the vehicle it's a net benefit why would
00:06:03
you continue with
00:06:04
it now this is even though it has a lot
00:06:09
of decoration it's a fairly simple
00:06:12
component we have that structure which I
00:06:14
showed you below we have these a surface
00:06:17
trim pieces that then attach to the
00:06:19
structure we have a very simple bin now
00:06:22
the one thing is this bin this is not a
00:06:25
drop in this is actually part of that
00:06:28
structure that I had showed you so
00:06:30
that's one component that comes all
00:06:35
up this is live stitching on this so it
00:06:38
feels like tire rubber however I don't
00:06:41
like that in this vehicle however it
00:06:45
does give you a very nice style and I'm
00:06:47
certain that it would be good for
00:06:49
cleanability going through the
00:06:53
future now I can't take this apart any
00:06:55
more than we already have I wanted to
00:06:57
point out a couple of the decorative
00:06:58
features
00:07:00
look at this reddish orange decorative
00:07:04
trim now there's a possibility that's a
00:07:07
two shop that almost looks like it's
00:07:09
painted which means it's probably a
00:07:10
secondary component that is applied to
00:07:13
the
00:07:13
Top If you really look at this you'll
00:07:16
notice that this leg is longer than this
00:07:20
leg which means that those are unique
00:07:22
components it's not one part being used
00:07:25
in two different locations but it's very
00:07:27
very close to being one part
00:07:30
now the question is well why didn't they
00:07:32
just connect it and make one big part
00:07:35
why have a split and if you had a split
00:07:37
why I make two different ones that just
00:07:39
caus complexity on the assembly line I
00:07:42
don't know there might be a reason in
00:07:44
there structurally it might just be
00:07:45
because of the style they liked the look
00:07:47
of that that type of an issue carries
00:07:49
over to the cup
00:07:51
holder you'll see that this cup holder
00:07:54
is not basically rectangular it's not
00:07:57
squared off on the corners it's opened
00:07:59
up because it being because of it being
00:08:01
open like that this front piece is a
00:08:05
different shape than the rear again that
00:08:08
causes complexity on the assembly line
00:08:10
it causes an operator to have to think
00:08:12
about how they're actually putting it
00:08:17
together even with those features this
00:08:20
is still a fairly simple assembly a
00:08:24
simple assembly has nice styling it's
00:08:27
appealing to the customer this type of
00:08:29
assembly does not reduce the selling
00:08:31
price of the
00:08:32
vehicle now this is in high contrast to
00:08:35
what we've seen on Kia and on
00:08:40
Hyundai every center console that I've
00:08:42
torn down from them have been overly
00:08:45
complicated uh I do believe that we have
00:08:47
a video with Tyler going through what he
00:08:49
saw on the onic 5 there's so much to do
00:08:53
with that assembly that to the customer
00:08:57
they're paying a lot of money that the
00:08:59
customer really doesn't see I did want
00:09:01
to show that on the hinge in order for
00:09:04
this to work for this hinge this hinge
00:09:06
has that internal tension that holds it
00:09:08
in place it's not a cheap hinge that
00:09:10
will allow this to just fall down and
00:09:12
slam down this is the hinge from that
00:09:16
hondai
00:09:17
ionic um again this has a latch it still
00:09:21
has this springloaded element here I
00:09:24
don't know why these two pieces are
00:09:26
separated because the way this is pinned
00:09:30
together it could not actually move
00:09:32
independently I would say that this is
00:09:36
overdesigned and overbuilt for what it
00:09:38
needs to be for an armrest LD so it
00:09:42
would be nice to really see what is in
00:09:44
this hinge but I can guarantee you it is
00:09:47
far simpler than what is here in the
00:09:49
hyai
00:09:50
ionic so I was looking at this silver
00:09:54
graphite color here and I want to
00:09:56
determine if it was painted looking in
00:09:58
from what I see on the back side yes I
00:10:00
would say this is a painted part now
00:10:03
here's a debate I have worked with some
00:10:06
injection molding resins that enable
00:10:09
this look without having to use paint
00:10:11
but there's a problem if I have an
00:10:13
injection molding resin that I am
00:10:16
injecting into a part you run the risk
00:10:18
of having flow lines where basically as
00:10:21
that material is Flowing before it cools
00:10:23
off the metallic kind of follows how it
00:10:26
flowed into the part and you could see
00:10:28
that
00:10:30
there's another problem however I've
00:10:32
worked with some customers that they did
00:10:34
not want to invest in the paint line so
00:10:36
just injection M apart in whatever color
00:10:38
we need and i' would say okay you're a
00:10:41
low volume producer right yeah we want
00:10:43
to get to 50,000 vehicles per year like
00:10:46
okay 50,000 vehicles per year how many
00:10:49
colors do you want we want five colors
00:10:52
five colors at 50,000 per year so now
00:10:54
it's 10,000 per color okay how many
00:10:59
parts do you want to make at a time well
00:11:01
we don't want to make all of them at
00:11:02
once so basically we want a batch every
00:11:05
week so I'm like okay so you want a few
00:11:08
of those every week of five different
00:11:12
colors so maybe you want 500 per week of
00:11:16
each color or less every time I have to
00:11:21
change color I have to purge the
00:11:23
injection molding machine all of the
00:11:26
resin that's already in there if it's
00:11:28
colored resin has to get out so the way
00:11:31
I do that is I just start running
00:11:34
through the next color of resin the
00:11:37
parts not Parts but just raw material
00:11:40
starts pouring out of the machine and it
00:11:42
kind of looks like a marble all the
00:11:44
different colors mixed together and I
00:11:45
have to purge and Purge and Purge until
00:11:47
it comes out all one solid color I can
00:11:50
easily go through a 100 lounds of resin
00:11:54
purging out of that machine in order to
00:11:55
change my color okay so now I have to
00:11:58
throw away 100 lb of resin every batch
00:12:01
of 500
00:12:03
Parts guess what that might be equal to
00:12:06
or half the amount of all the resin
00:12:07
that's required to make those 500 parts
00:12:10
so that affects your cost the final
00:12:13
piece cost whereas if I painted them I
00:12:17
injection molded them all in the same
00:12:18
color I don't have to do those purges
00:12:21
but I have to invest in a paint line and
00:12:24
it is much easier to change over the
00:12:27
color that's in a paint cup or in a
00:12:29
paint machine then it is to cycle
00:12:31
through all of that
00:12:32
resin so these are the options that I
00:12:35
would say my customer has you might say
00:12:37
that you're only building 50,000 per
00:12:39
year if you're doing that your parts are
00:12:41
going to be more expensive your parts
00:12:44
are going to have to be painted you
00:12:46
don't have the volume to justify
00:12:48
injection M injection molding multiple
00:12:51
colors at low volume now unfortunately I
00:12:53
cannot really dig into the seat so there
00:12:55
are only a few things that I can point
00:12:57
out just by looking from the bottom
00:13:00
but there are a couple points that I
00:13:01
would like to make
00:13:03
mention the first you'll notice that
00:13:06
everything is painted all of the metal
00:13:09
structure even the hidden metal
00:13:11
structure is painted if we're in the
00:13:13
United States that is not common almost
00:13:17
all of our hidden structure would just
00:13:19
be stamped and left raw the only thing
00:13:23
that would be painted would be the
00:13:25
tracks and maybe some of the pieces in
00:13:27
the Riser of the lifting mechanism
00:13:29
if they can possibly be visible but we
00:13:32
would not paint this pan or these other
00:13:34
brackets now I've talked to my customers
00:13:36
around the world about why you would
00:13:39
paint some of them I've tried to
00:13:41
encourage them to get rid of painting
00:13:43
all those other components some of them
00:13:46
I can't now one thing that I
00:13:48
learned this is actually a cultural
00:13:51
decision there are some areas in the
00:13:54
world where customers specifically on
00:13:57
the secondary Market would literally go
00:14:00
into all of the Hidden areas and if they
00:14:02
see any type of rust they would use that
00:14:04
as an argument or a bargaining chip in
00:14:06
the sales price of the vehicle so for
00:14:09
them they're actually protecting their
00:14:12
customer down the line by having all of
00:14:15
those components painted even though it
00:14:18
really doesn't matter for that culture
00:14:21
it was important all right so this
00:14:25
vehicle I don't really know where its
00:14:28
Market is is I do believe this is
00:14:30
actually made in Mexico I don't know if
00:14:32
this is being sold primarily on the
00:14:37
North and South American continent or if
00:14:38
this is for export but having these
00:14:41
components painted in this area is not
00:14:45
really required and it's a cost they
00:14:46
you're incurring because of that
00:14:48
decision so now let's look at these
00:14:51
brackets here is a bracket on top of a
00:14:55
pipe floating over top of this pan the
00:14:59
only thing I see that bracket is doing
00:15:00
is it is holding these wire harness
00:15:04
attachments could those wire harness
00:15:06
attachments have attached directly into
00:15:09
the pan many of my customers they do
00:15:12
attach directly into the pan so this is
00:15:15
a decision there might be other
00:15:17
considerations in this total assembly
00:15:20
but remember we have a stamped bracket
00:15:23
that is being painted I have one two
00:15:27
three screw locations in order to attach
00:15:29
it and all it's doing is supporting
00:15:32
snapping in these wire harness
00:15:35
connections I would Target that bracket
00:15:37
for elimination I don't believe that it
00:15:39
should be there all right we have
00:15:41
another bracket and this is a little
00:15:44
different we have a bracket that is
00:15:47
supporting a blower we have a rubber
00:15:50
duct that is then venting this blower
00:15:52
into the seat cushion so that's your
00:15:54
ventilated
00:15:55
seat the bracket I would make the same
00:15:58
argument in so let's look at
00:16:01
something this is from a
00:16:05
Ford this is the suspension mat the vent
00:16:10
where we have our vent here they stuck
00:16:12
their vent right there into the
00:16:14
foam and their blower
00:16:17
motor
00:16:18
attaches directly to that component so
00:16:22
what do I not have here I don't have
00:16:24
this duct and I don't have the metal
00:16:26
bracket those are things that I would
00:16:28
question and target for elimination in
00:16:31
this
00:16:32
assembly when would I say a duct is a
00:16:35
good
00:16:37
idea this is for Marian but this is
00:16:40
actually common for Kia and Hyundai we
00:16:43
have Ducks
00:16:46
but these ducks go to the cushion and
00:16:49
also up to the seatback enabling them to
00:16:51
have just one blower so here we have the
00:16:54
front fascia now looking at this front
00:16:56
fascia this is mostly injection molded
00:17:00
components lots of times we need to be a
00:17:02
fairly flexible injection molded
00:17:04
assembly so faes are generally made from
00:17:08
TPO uh which is a little more of a
00:17:10
flexible version of
00:17:11
polypropylene looking through this
00:17:14
assembly it's it's hard to really give
00:17:16
you an understanding but if you've ever
00:17:19
popped the fascia off of your vehicle
00:17:22
these
00:17:24
screws are traditionally not used here
00:17:28
like lots of times we'll have the little
00:17:30
plastic push pin Clips which to be
00:17:33
honest may break or pop away as you're
00:17:36
trying to remove them but driving all of
00:17:39
these
00:17:40
screws isn't as common much
00:17:43
anymore now this component is an
00:17:45
injection molded
00:17:47
assembly that injection molded assembly
00:17:49
you can see a witness line here you can
00:17:51
see a witness line here that's from Tool
00:17:54
action that is moving however normally
00:17:57
you do not see any type of structural
00:18:00
ribbing on the faes now I talked about
00:18:04
that in a video a while ago about the
00:18:06
structural ribbing on the doors and we
00:18:08
looked at the cybertruck and the way
00:18:10
they were able to separate the ribs from
00:18:12
the a
00:18:13
surface if I had the ribs or if I had
00:18:17
any of these towers attached directly to
00:18:19
this component you have the possibility
00:18:21
of actually seeing that through the
00:18:23
paint on the a surface so this is a
00:18:27
reinforcement piece that that gives you
00:18:29
the undercuts gives you the attachment
00:18:32
but this is actually welded into this
00:18:34
outside component the welding if you
00:18:37
have your parameter set improperly may
00:18:39
be visible on the a surface but it's
00:18:42
less likely to be visible compared to
00:18:44
actually structural ribbing or any type
00:18:46
of dog house features and undercuts that
00:18:48
you would need
00:18:53
here also it makes it for a less
00:18:55
expensive tool this is a very large tool
00:18:58
the more action you put into the tool it
00:19:02
affects cycle time for molding the part
00:19:03
and it affects the cost of the tool
00:19:05
itself so sometimes you'll make the
00:19:07
determination that welding on this piece
00:19:10
which is made in a smaller injection
00:19:11
molding tool is less expensive than
00:19:15
trying to have the one large tool the
00:19:17
other nice thing is if you end up
00:19:19
changing anything in here you can change
00:19:22
just the small tool and weld it back in
00:19:24
place so if there was some other module
00:19:26
some other version I can change just
00:19:29
this bracket so as I've said in the past
00:19:31
there's a couple things you need to look
00:19:32
at there is the what and the how now the
00:19:36
what is basically what is leaving the
00:19:38
assembly line what you are purchasing as
00:19:40
a customer there is the how all of the
00:19:44
decisions and the manufacturing
00:19:45
processes that make up that what for me
00:19:49
it is the how that is the most important
00:19:52
if you tell me the what is a $300,000
00:19:54
vehicle with all the decorative trim All
00:19:57
The Bling okay I can support that but I
00:20:01
can support that using some Innovative
00:20:04
and lowcost
00:20:05
house sometimes you'll say well we want
00:20:07
the Bare Bones Basics but yet if you do
00:20:10
it in a complicated way the customer is
00:20:13
still getting the Bare Bones Basics but
00:20:15
I am killing myself in cost of assembly
00:20:18
cost of
00:20:19
manufacturing because of how I decided
00:20:21
to put it together so though we cannot
00:20:24
tear down this vehicle much more than we
00:20:26
already have I don't know how much more
00:20:28
we actually be able to say about the byd
00:20:30
shark I do want to say that it's very
00:20:32
very important to not only look at the
00:20:34
what what you're purchasing if you're
00:20:36
someone in my shoes that how is the most
00:20:40
interesting part uh and that is what I'd
00:20:42
like to focus on and I hope you enjoy
00:20:45
seeing some of the things that I see so
00:20:47
thank you for watching on real live and
00:20:49
I hope you have a good day
00:20:51
[Music]
00:20:57
[Music]
